Perforated packaging

ABSTRACT

Packaging boxes and packaging methods for providing the ability to quickly open tape-sealed packages while eliminating the necessity for cutting tools and potential cutting injuries associated with these cutting tools. Through the inclusion of at least one perforated access panel in at least one end portion of a corrugated packaging box, hand access is provided to an end of the tape allowing the length of tape to be completely removed without the use of any cutting tools. The at least one perforated access panel can include a punch-in section and a tear-away section wherein a tape end is positioned over at least a portion of the punch-in section. The punch-in section can be pushed inwards providing access to the tear-away section. Pulling on the tear-away section results in the tear-away section and correspondingly, the tape being torn from the packaging box.

FIELD OF THE INVENTION

The invention relates to tape-closed packaging and more particularly to packaging having perforated cut-outs promoting tape removal during package opening.

BACKGROUND OF THE INVENTION

Packages and boxes made of corrugated paperboard are well known and are frequently used in a wide variety of applications including, for example, the packaging of food products for shipment and storage. The use of corrugated paperboard in these applications is popular because the paperboard allows for large quantities of boxes to be made quickly and inexpensively. In addition, boxes made of corrugated paperboard may be recycled or used repeatedly such that disposal costs are reduced and/or eliminated.

When loaded boxes arrive at their destination, the boxes are typically unloaded such that packaged goods can be accessed for use or sale. In order to maintain the packaged goods within the box, the boxes are typically closed using an adhesive or through application of tape. When opening boxes that have been closed with an adhesive or tape, a person often must utilize a cutting tool such as, for example, a knife, scissors, razor blade and the like. Use of these cutting tools can be inconvenient as there is a risk to potential damage to the packaged goods while at the same time increasing the potential for cutting injuries often associated with said cutting tools.

BRIEF SUMMARY OF THE INVENTION

Corrugated packaging and the associated methods disclosed herein provide an ability to quickly open packages sealed with tape while eliminating the potential for cutting injuries typically associated with cutting tools. Through the inclusion of a perforated access panel in at least one end portion of a corrugated package, hand access is provided to an end of the tape allowing the length of tape to be completely removed without the use of any cutting tools.

In one aspect, the present disclosure relates to a packaging box comprising corrugated paperboard for retaining product during shipment and storage. The packaging box includes at least one perforated access panel in an end wall of the packaging box. The at least one perforated access panel can comprise a punch-in section and a tear-away section wherein a tape end is positioned over at least a portion of the tear-away section. The punch-in section can be pushed inwards providing access to the tear-away section. Pulling on the tear-away section results in the tear-away section being torn from the packaging box wherein the tape end is simultaneously ripped from the packaging box allowing the length of tape to be removed from the packaging box.

In another aspect, the present disclosure provides methods for quickly and safely opening a packaging box. Generally, the methods provide for accessing a tear-away section of a perforated access panel wherein removing the tear-away section simultaneously removes an end portion of a length of tape. Access to the tear-way section can be gained by pushing in a knock-out portion of the perforated access panel.

In another aspect, the present disclosure provides for a packaging system for use during shipment and storage of goods. The packaging system can comprise a corrugated paperboard box for placement of the goods within and a length of tape for holding top flaps of the corrugated paperboard box in a closed configuration. The corrugated paperboard box can comprise at least one perforated access panel allowing for quick and safe removal of the length of tape when accessing the interior of the corrugated paperboard box.

As used throughout the specification, the terms top and bottom generally refer to a shipping or storage orientation of a packaging box and to distinguish opposed sides of a packaging box. The terms top and bottom are not intended to limit a packaging box to a particular shipping and/or storage orientation. With some products contained within the packaging box, shipping and/or storage orientation will have no effect upon the product such the top and bottom surfaces are interchangeable as there may be no preferred shipping orientation.

The various embodiments and aspects of the present disclosure are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:

FIG. 1 is a perspective view of a prior art packaging box having a top portion of the packaging box closed with an adhesive.

FIG. 2 is a perspective view of a prior art packaging box having a top portion of the packaging box closed with a length of tape.

FIG. 3 is a perspective view of an embodiment of a packaging box having at least one perforated access panel for providing access to a tape end of a length of tape used to closed the packaging box.

FIG. 4 is a top view of the packaging box of FIG. 3 in an unassembled flat configuration.

FIG. 4 b is an enlarged view of a perforated access panel in the unassembled flat configuration of FIG. 4.

FIG. 5 is a top view of an embodiment of a packaging box having at least one perforated access panel in an unassembled flat configuration.

FIG. 6 is an enlarged top view of the packaging box of FIG. 5 taken at Detail 6 of FIG. 5.

FIG. 7 is a top view of an embodiment of a packaging box having at least one perforated access panel in an unassembled flat configuration.

FIG. 8 is a top view of an embodiment of a packaging box having at least one perforated access panel in an unassembled flat configuration.

FIG. 9 is a top view of an embodiment of a packaging box having at least one perforated access panel in an unassembled flat configuration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As illustrated in FIGS. 1 and 2, a packaging box 100 of the prior art can comprise a top surface 102, a bottom surface 104, a pair of side surfaces 106 a, 106 b and a pair of end surfaces 108 a, 108 b. Top surface 102 can comprise a pair of hinged major flaps 110 a, 110 b rotatably attached to the corresponding side surface 106 a, 106 b at a hinge member 112. Additionally, top surface 102 can comprise a pair of hinged minor flaps 113 a, 113 b rotatably attached to the corresponding end surfaces 108 a, 108 b at a hinge member 115. Hinge member 112 and hinge member 115 generally comprise a scored portion 114 or scored line distinguishing the hinged flaps from the corresponding side or end surface. Though not depicted in detail, bottom surface 104 can substantially resemble top surface 102 in construction and appearance. Packaging box 100 can comprise suitable materials of construction such as, for example, single or multi-wall construction utilizing cardboard, paperboard, corrugated paper, chipboard and combinations thereof.

As illustrated in FIG. 1, packaging box 100 is formed into a closed configuration 116 by rotatably folding the hinged minor flaps 113 a, 113 b toward one another wherein the hinged major flaps 110 a, 110 b are folded over hinged minor flaps 113 a, 113 b and into proximity such that the hinged major flaps 110 a, 110 b meet along a sealing interface 118. As illustrated in FIG. 1, hinged major flaps 110 a, 110 b can be retainably maintained at sealing interface 118 through the application of a suitable adhesive on a bottom side of hinged major flaps 110 a, 110 b to the hinged minor flaps 113 a, 113 b wherein the hinged minor flaps 113 a, 113 b provide further structural support.

As illustrated in FIG. 2, hinged major flaps 10 a, 10 b can be similarly formed and retained into closed configuration 116 using a length of packing tap 120 long enough to cover the sealing interface 118 and at least partially wrap over and attach to the end surfaces 108 a, 108 b. Packing tape 120 can comprise a suitable packing tape such as, for example, packing tape available from Minnesota Mining and Manufacturing of St. Paul, Minn.

Packaging box 100, as illustrated in FIG. 1, can require the use of specialized packaging equipment to properly apply the adhesive for closing hinged major flaps 110 a, 110 b. The adhesive may require application at increased temperatures, which can provide a risk to personnel handling packaging box 100. When packaging box 100 is to be opened, generally a tearing force must be applied to the hinged major flaps 110 a, 110 b so as to separate the hinged major flaps 110 a, 110 b from the hinged minor flaps 113 a, 113 b, which can result in tearing of the hinged major flaps 110 a, 110 b such that full access is not provided to the packaging box 100. The tearing action also generally requires the tearing force be applied by the individual opening packaging box 100 and in some instances may require increased strength and exertion by the individual. In addition, packaging box 100 can be opened through the use of cutting tools to remove the hinged major flaps 110 a, 110 b and the hinged minor flaps 113 a, 113 b from the packaging box 100. By necessity, these cutting tools have sharp edges and/or points wherein use of these cutting tools necessarily increases the potential for injuries to a user such as, for example, cuts and/or piercings to the individual opening the packaging box 100. In addition, damage can be unintentionally inflicted upon the goods and products contained within the packaging box 100 as the cutting tool is utilized to access the interior of the packaging box 100.

Packaging box 100, as illustrated in FIG. 2, generally requires the use of cutting tools such as, for example, a knife, razor, scissors and the like, to cut the packing tape 120 along sealing interface 118. As said cutting tools have sharp edges by necessity, use of said cutting tools can result in injuries such as, for example, cuts and piercings to individuals opening the packaging box 100. In addition, damage to products contained within the packaging box 100 can be inflicted as the cutting tool is used to cut the packing tape 120. Individuals opening packaging box 100 can attempt to open the packaging box by tearing at a tape end 122 of the packing tape 120 but this can be inefficient resulting in increased time for the individual to open the packaging box 100.

A representative packaging box 200 of the present invention is illustrated in FIGS. 3 and 4. Packaging box 200 generally resembles packaging box 100 in that packaging box 200 comprises top surface 202, a bottom surface 204, a pair of side surfaces 206 a, 206 b and a pair of end surfaces 208 a, 208 b. Top surface 202 generally comprises a pair of hinged major flaps 210 a, 210 b rotatably attached to the corresponding side surface 206 a, 206 b at a hinge member 212 and a pair of hinged minor flaps 213 a, 213 b attached to the corresponding end surface 208 a, 208 b at hinge member 212. Hinge member 212 generally comprises a scored portion 214 or scored line distinguishing the hinged flap from side surface. Bottom surface 204 can substantially resemble top surface 202 in construction and appearance. Packaging box 200 can comprise suitable materials of construction such as, for example, single or multi-wall construction utilizing cardboard, paperboard, corrugated paper, chipboard and combinations thereof. End surface 208 a can comprise a perforated access panel 216 having a punch-in portion 218 and a tear-away portion 220 as illustrated in FIG. 3 or, alternatively, both end surface 208 a and end surface 208 b can comprise at least one perforated access panel 216 as illustrated in FIG. 4.

As illustrated in FIG. 3, packaging box 200 can be formed into a closed configuration 222 by rotatably folding the hinged minor flaps 213 a, 213 b toward one another wherein the hinged major flaps 210 a, 210 b are folded over the hinged minor flaps 213 a, 213 b and into proximity such that the hinged major flaps 210 a, 210 b meet along a sealing interface for example sealing interface 118 shown in FIG. 1. Hinged major flaps 210 a, 210 b can be retainably maintained at sealing interface 118 using a length of packing tap 120 long enough such that when the sealing interface 118 is fully covered, the tape end 122 wraps over and at least partially covers the tear-away portion 220 of the perforated access panel 216. In one presently preferred embodiment, tape end 122 does not wrap over and/or cover the punch-in portion 218.

As illustrated in FIG. 4, packaging box 200 can be stored and/or transported in a flat configuration 224 or alternatively, a partially assembled configuration wherein perimeter tab 234 is pre-attached to the inside of side surface 206 b using a suitable attachment method such as, for example, use of an adhesive and/or tape. As illustrated in FIG. 4, packaging box 200 can further comprise a pair of bottom minor flaps 228 a, 228 b and a pair of bottom major flaps 230 a, 230 b. The various surfaces and flaps can be distinguished by scored lines 232. Packaging box 200 can further comprise a perimeter attachment tab 234 for operatively joining end surface 208 a with side surface 206 b.

As illustrated in FIGS. 3, 4 and 4 b, access panel 216 and more specifically, punch-in potion 218 and tear-away portion 220 are defined by a first perforated link 235 and a second perforated link 237 wherein each perforated link comprises a plurality of spaced apart perforations 236 extending fully through the thickness of flat configuration 224. The perforations 236 can have a perforation length 238 from about 0.067 inches to about 1.0 inches. Perforation length 238 and perforation spacing 240 between perforations 236 can be specifically selected to provide the necessary retaining strength such that neither the first perforated link 235 or second perforated link 237 are pushed out or broken by products stored and transported by packaging box 200 while providing for easy separation along first perforated link 235 and second perforated link 237 to a person intentionally accessing the interior of packaging box 200. Product characteristics that can effect the design of perforated access panel 216 can include, for example, product size, product layout, product shape, product weight and product quantity.

In use, the flat configuration 224 is folded inwardly along the scored lines 232 such that side surfaces 206 a, 206 b are in a substantially parallel relation while end surfaces 208 a, 208 b are also arranged in a substantially parallel orientation. Perimeter attachment tab 234 is attached to an inner surface of side surface 206 b using a suitable attachment mechanism such as, for example, an adhesive or tape. Bottom minor flaps 228 a, 228 b are folded inwardly wherein the bottom major flaps 230 a, 230 b are folded inwardly to capture the bottom minor flaps 228 a, 228 b. The bottom major flaps 230 a, 230 b can be retained in an inwardly folded, retained relation to define bottom surface 204 using suitable attachment techniques such as, for example, the use of adhesives and/or tape as previously described with respect to packaging box 100. Once the bottom surface 204 has been defined, products can be loaded into an interior portion of the packaging box 100. Products can comprise bulk packaged goods such as, for example, refrigerated or frozen dough products or stacked goods such as, for example, trays of refrigerated or frozen dough products.

Once packaging box 200 has been loaded with product, the hinged minor flaps 213 a, 213 b are rotatably folded toward one another such that hinged major flaps 210 a, 210 b can be folded over the hinged minor flaps 213 a, 213 b and approximated along sealing interface 118 as described previously with respect to packaging box 100. A length of tape 120 is placed over the sealing interface 118 and wrapped onto the end surfaces 208 a, 208 b such that the tape end 122 resides at least partially over the tear-away portion 220 of the perforated access panel 216. At this point, packaging box 200 is prepared for transportation and storage.

At time of use, an individual accesses the product with packaging box 200 by breaking the second perforated link 237 through pushing the punch-in portion 218 of the perforated access panel 216 into the interior of packaging box 200. By pushing in the punch-in portion 218, the tear-away portion 220 becomes accessible for grabbing by the individual. The individual grabs the exposed tear-away portion 220 and rips the tear-away portion 220 away from the end surface 208 a along the first perforated link 235. As the tear-away portion 220 is removed, the tape end 122 remains attached to the tear-away portion 220 such that the length of tape 120 begins to be torn from the packaging box 200. Through continued pulling of the tear-away portion 220, the length of tape 120 is removed along the length of sealing interface 118 allowing both the hinged major flaps 210 a, 210 b and hinged minor flaps 213 a, 213 b to be folded back along the scored lines 232 connecting the hinged major flaps 210 a, 210 b with the side surfaces 206 a, 206 b and the hinged minor flaps 213 a, 213 b with the end surfaces 208 a, 208 b so as to expose the interior of packaging box 200 and allow access to the products.

As illustrated in FIGS. 5, 6, 7 and 8, packaging box 200 can comprise a variety of alternative configurations for the perforated access panel based upon product characteristics such as, for example, product size, product layout, product shape, product weight and product quantity. With reference to FIGS. 5 and 6, packaging box 200 can comprise at least one perforated access panel 242 having a generally semi-circle shaped punch-in portion 244 and a generally rectangular tear-away portion 246. In another alternative embodiment illustrated in FIG. 7, packaging box 200 can comprise a perforated access panel 248 having a generally rectangular punch-in portion 250 and a generally rectangular tear-away portion 252. In another alternative embodiment illustrated in FIG. 8, packaging box 200 can comprise a perforated access panel 254 having a generally rectangular tear-away portion 256 and a punch-in portion 258 wherein punch-in portion 258 comprising a first punch-in portion 258 a and a second punch-in portion 258 b. As illustrated in FIG. 8, tear-way portion 256 can be positioned in the end surfaces 208 a, 208 b such that scored line 232 is used to partially define the tear-away portion 256.

In another embodiment, packaging box 200 can comprise perforated access panels for providing access to one or both of the top surface 202 and bottom surface 204 as illustrated in FIG. 9. Packaging box 200 comprises a pair of top perforated access panels 258 a, 258 b and a pair of bottom perforated access panels 260 a, 260 b. As depicted in FIG. 9, the top perforated access panels 258 a, 258 b and bottom perforated access panels 260 a, 260 b can have a similar configuration with a generally semi-circle shaped punch-in portion 262 and a generally semi-circle shaped tear-away portion 264. In use, bottom surface 204 can be closed using tape 120, as previously described with respect to top surface 202, wherein tape end 122 resides at least partially over one or both of bottom perforated access panels 260 a, 260 b. Packaging box 200 can be used advantageously with products wherein the shipping and/or storage orientation of the products such as, for example, right side up or upside down, is unimportant. In this manner, product can be accessed through the top surface 202 or bottom surface 204 depending upon which orientation is most convenient to the person opening packaging box 200.

It will thus be seen according to the invention a highly advantageous packaging box and methods for packaging. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. 

1. A packing container comprising: a box having a top surface, a bottom surface, a first side surface, a second side surface, a first end surface and a second end surface, the top surface defined by a first hinged flap and a second hinged flap formed in a closed configuration wherein the first hinged flap is attached to the first side surface and the second hinged flap is attached to the second side surface; and a length of tape having a first tape end and a second tape end, wherein the length of tape retains the first hinged flap and second hinged flap in the closed configuration, and wherein the first end surface comprises a first access panel defined by a first perforated link, said first access panel having a punch-in portion abutting a tear-away portion, said punch-in portion and tear-away portion separated by a second perforated link, the first tape end positioned at least partially over the tear-away portion and first end surface, said punch-in portion separable from the first end surface and tear-away portion at the second perforated link, and said tear-away portion and first tape end separable from the first end surface at the first perforated link.
 2. The packing container of claim 1, further comprising a second access panel on the second end surface, the second access panel resembling the first access panel such that a second tape end is positioned at least partially over the tear-away portion of the second access panel.
 3. The packing container of claim 2, wherein the punch-in portion on the second access panel is separable from the tear-away portion on the second access panel and wherein the tear-away portion and second tape are separable from the second end surface.
 4. The packing container of claim 1, wherein the box is manufactured from a packing material selected from the group comprising: cardboard, paperboard, corrugated paper, chipboard and combinations thereof.
 5. The packing container of claim 1, wherein the punch-in portion is defined by the first perforated link and the second perforate link such that the punch-in portion comprises a shape selected from the group comprising: a rectangle, a square, a semi-circle, a triangle and combinations thereof.
 6. The packing container of claim 1, wherein the first end surface comprises a pair of first access panels, wherein one first access panel corresponds to the top surface of the box and one first access panel corresponds to the bottom surface of the box.
 7. The packing container of claim 1, wherein the first perforated link and the second perforated link comprise a plurality of perforations having a perforation length, wherein the perforation length is from about 0.067 inches to about 1.0 inches.
 8. A method for gaining access to goods within a packing container comprising: providing an access panel in an end surface of a packing container, the access panel having a punch-in portion and a tear-way portion wherein the packing container is retained in a closed configuration with a length of packing tape having a tape end at least partially covering the tear-away portion; pushing in the punch-in portion to expose a gripping end on the tear-away portion; and ripping the tear-away portion from the end surface such that the tape end is torn from the packing container wherein further ripping of the tear-away portion removes the length of packing tape from the packing container.
 9. The method of claim 8, wherein pushing in the punch-in-portion comprises tearing a perforated link between the punch-in-portion and the tear-away portion wherein the gripping end is exposed.
 10. The method of claim 8, wherein ripping the tear-away portion comprises tearing a perforated link between the tear-away portion and the end surface.
 11. The method of claim 8, wherein providing an access panel in the end surface comprises providing an pair of access panels, a first access panel provided in a first end surface and a second access panel provided in a second end surface, wherein the length of packing tape at least partially covers the tear-away portion of both the first access panel and the second access panel when the packing container is retained in a closed configuration.
 12. The method of claim 11, wherein providing a pair of access panels comprises providing a pair of access panels in both the first end surface and the second end surface, the first end surface and the second end surface each comprising a top access panel and a bottom access panel wherein a top length of packing tape at least partially covers the tear-away portion of the top access panel on both the first end surface and the second end surface and wherein a bottom length of packing tape at least partially covers the tear-away portion of the bottom access panel on both the first end surface and the second end surface when the packing container is retained in a closed configuration.
 13. The method of claim 8, further comprising: loading the packing container with a bulk packaged good and closing the packing container with the length of packing tape such that the packing container is retained in the closed configuration with the tape end at least partially covering the tear-away portion.
 14. The method of claim 13, wherein the bulk packaged good is selected from the group comprising: a frozen dough product and a refrigerated dough product.
 15. A packing container comprising: a box having a top surface, a bottom surface, a first side surface, a second side surface, a first end surface and a second end surface, the top surface defined by a first hinged flap and a second hinged flap formed in a closed configuration wherein the first hinged flap is attached to the first side surface and the second hinged flap is attached to the second side surface; and a length of tape having a first tape end and a second tape end, the length of tape retains the first hinged flap and second hinged flap in the closed configuration such that the first tape end resides on the first end surface and the second tape end resides on the second end surface, and a means for accessing the first tape end on the first end surface without grabbing the first tape end; and a means for removing the first tape end from the end surface without grabbing the first tape end. 